螺旋锥齿轮磨削界面力热耦合与表面性能生成机理研究
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摘要
螺旋锥齿轮是国防、能源、运载、装备制造业及交通等领域中重要装备的关键零件,其精密加工方法广泛采用数控磨削。由于螺旋锥齿轮空间形状和加工过程复杂,其磨削关键技术长期被美国Gleason等公司垄断,我国在近十年也研发出了螺旋锥齿轮磨削机床,但磨削质量的提高一直我国螺旋锥齿轮制造的难点。美国Gleason公司磨齿机加工螺旋锥齿轮可达2级精度,而国内目前螺旋锥齿轮磨削仅能达4-6级精度,易产生磨削表面粗糙度不稳定、磨削烧伤与裂纹等表面质量缺陷。螺旋锥齿轮磨齿质量与磨齿机及磨齿工艺密切相关,提高磨齿机本体精度及认识磨齿机理、实现磨齿参数的最优预控是解决我国螺旋锥齿轮磨削质量问题的根本途径,而我国目前在螺旋锥齿轮磨削机理及工艺参数控制方面的研究尤其缺乏。本论文以提高螺旋锥齿轮磨削表面质量为目的,根据螺旋锥齿轮加工原理与工艺特点,开展螺旋锥齿轮磨削界面力热耦合与表面性能生成机理的研究,主要内容叙述如下。
螺旋锥齿轮磨削界面力热耦合机理研究。根据螺旋锥齿轮六轴五联动数控加工原理,进行了螺旋锥齿轮磨削调整计算与磨削机理分析,建立了物理意义上的磨削力计算公式,应用单磨粒热模型得出了热量分配比,采用矩形分布热源计算了磨削热流量；采用数值有限元方法建立了螺旋锥齿轮3D单齿模型。在此基础上,运用热传导理论、热弹塑性理论,对螺旋锥齿轮磨削温度场进行了力热耦合的有限元仿真分析,并进行了实验验证。采用PRANDTL-REUSS方法,建立了磨削界面应力应变场本构关系,仿真分析了螺旋锥齿轮不同齿面磨削位置的应力与应变场分布。
螺旋锥齿轮磨削残余应力及其影响因素研究。结合螺旋锥齿轮啮合原理,运用矢量分析法建立齿面方程,通过“自底向上”的实体建模方法建立了分析螺旋锥齿轮磨削残余应力的实体模型。根据VonMises屈服准则、Mises流动准则和MISO模型建立了齿轮的材料关系模型。按照Gleason接触原理,得出了磨削基本参数的数学模型。基于力热耦合,对螺旋锥齿轮磨削残余应力进行了模拟分析,并进行了实验验证,得出了磨削残余应力随磨削工艺参数变化的规律。
螺旋锥齿轮磨削表面粗糙度研究。运用空间坐标变换原理,通过构造弧齿锥齿轮展成磨削的齿面坐标系、刀具切削面和磨削啮合方程,建立了磨削齿面的数学模型。根据磨削表面粗糙度的包络形成机理及其影响因素分析,采用齿面网格节点的约束求解法计算磨削加工轨迹；然后,由沿齿高方向的各横向截面上2D理论残留面积高度,得出3D理论残留面积高度,并考虑塑性侧向隆起现象,建立了螺旋锥齿轮磨削表面粗糙度的理论模型,并进行了实验验证,得出了磨削工艺参数对磨削表面粗糙度的影响规律。
螺旋锥齿轮磨削表层性态实验研究。运用力热耦合机理和位错理论,实验检测与分析了螺旋锥齿轮磨削表层显微硬度、组织的变化规律。通过对螺旋锥齿轮磨削温度、表层显微硬度与组织的检测与分析,得出了产生磨削烧伤的临界条件,获得了磨削烧伤与裂纹的生成规律与影响因素。
在上述的磨削界面力热耦合与表面性能生成机理研究基础上,进行了螺旋锥齿轮磨削工艺参数优选与磨削表面性能的实验优化分析。根据磨削正交实验结果,采用极差分析法和方差分析法,获得了螺旋锥齿轮磨削工艺参数优选配置。运用多元非线性最小二乘法,得出了磨削评价指标的实验回归模型。通过磨削表面性能的实验优化分析,磨削表面粗糙度Rα值比一般磨削工艺下要小0.1μm以下,其它磨削表面综合性能良好,为螺旋锥齿轮磨削表面质量的提高提供了依据。
Spiral bevel gears are the key parts in the national defense, energy, carry, equipment manufacturing and traffic areas, and so on. Its NC grinding method is widely used in its precision machining. As the space shape and processing of spiral bevel gears are complicated, the key grinding technologies have been monopolized by companies such as Gleason in the long term. The researcher in China has also developed the grinding machines of spiral bevel gears in the past decade, but it has been difficult to improve the grinding quality in manufacturing spiral bevel gears. The grinding quality of grinding tooth machines produced by Gleason Corporation is up to two precision, but at present, the ones in China is 4-6 precision, and the grinding surface roughness is not stable, it is easy to produce grinding burn, cracks, and other grinding surface quality defects. The grinding tooth quality of spiral bevel gears is closely related to the grinding tooth machine and process. Therefore, it is a fundamental way to solve our problems of grinding quality of spiral bevel gears that the body precision of grinding tooth machine is improved, the grinding tooth mechanism is understood, and the optimum pre-control of grinding parameters is achieved. However, now there is the serious lack of research on grinding mechanism and process parameters control in China. Taking increase grinding surface quality as the goal, according to the machining principle and process characteristic of spiral bevel gears, the thesis carries out the research on mechanism of thermo-mechanical coupling on grinding interface and surface performance generating of spiral bevel gears. The main contents are as follows.
Study on the mechanism of thermo-mechanical coupling on grinding interface of spiral bevel gears. According to the six axis five linkage NC machining principle of spiral bevel gears, its adjusting calculation and grinding mechanism analysis were made, and the physical meaning formulas of grinding forces were built. The heat distribution ratio was gotten by applying the thermal model of a single grinding grit, the heat flux was computed by using a rectangle distributing heat source, and the 3D single tooth model of spiral bevel gear was established by applying the finite element method. On the basis of researches of thermo-mechanical coupling, the grinding temperature field of spiral bevel gears was simulated and analyzed by using theories of heat conduction and the thermo-elastic-plastic, and it was verified by test. The constitutive relationships of stress and deformation fields on grinding interface have been set up by applying PRANDTL-REUSS method, and the distribution of stress and deformation fields at different location of grinding tooth were simulated and analyzed.
Study on the grinding residual stresses of spiral bevel gears and its influencing factors. Combined with meshing principle of spiral bevel gears, tooth surface equations were built by applying vector analysis method, and the solid model of analyzing grinding tooth residual stresses was established by applying the bottom-up solid modeling method. Based on the Von Mises yield criterion, the Mises flow rule and the MISO model, the material relationship model of the gears was built. According to the Gleason contact principle, the mathematical models of basic grinding parameters were gotten. Based on the thermo-mechanical coupling, the grinding residual stresses of spiral bevel gear were simulated and verified by experiment, and its change laws with the variation of process parameters were obtained.
Study on the grinding surface roughness of spiral bevel gears. According to the principle of space coordinates transformation, the mathematical models of grinding tooth of spiral bevel gear were set up by constructing the tooth surface coordinate system, cutting tool surface and grinding mesh equation of spiral bevel gears. Based on the cutter enveloping principle and analysis of influencing factors of surface roughness, the grinding trajectory was computed by using the constraint solving method of tooth surface grid nodes. Then, the 3D theoretical residual area heights were translated from 2D's ones of cross section along tooth depth, and the theoretical surface roughness model of grinding tooth of spiral bevel gear was built by taking into account a plastic side upheaval phenomenon, and the model was examined by test. The changing regularity of surface roughness affected by the grinding process parameters was reached.
Experiment study on the grinding surface layer behavior of spiral bevel gears. The change regularity of micro-hardness and structure of grinding surface layer of spiral bevel gears were tested and analyzed by applying the mechanism of the thermo-mechanical coupling and dislocation theory. Through the test and analysis of temperature, micro-hardness and structure of grinding surface layer of spiral bevel gears, the critical condition of grinding burn was obtained, and the generating rules and its influencing factors of grinding burn and cracks were gotten.
Based on the above study of mechanism of thermo-mechanical coupling on grinding interface and surface performance generating, the parameters optimization and the test optimal analysis of grinding surface performance of spiral bevel gears were carried out. According to the results of grinding orthogonal test, the optimizing configuration of grinding process parameters of spiral bevel gears was obtained by using range and variance analysis method. Then, the test regression models of grinding evaluating indicators were conducted by using multivariate nonlinear least squares method. Through the test optimal analysis of grinding surface performance, the value of grinding surface roughness Rαwas more less 0.1μm than ones of the average grinding process, and other comprehensive performance of grinding surface were better. These provided a basis for improvement of grinding surface quality of spiral bevel gears.
螺旋锥齿轮磨削界面力热耦合机理研究。根据螺旋锥齿轮六轴五联动数控加工原理,进行了螺旋锥齿轮磨削调整计算与磨削机理分析,建立了物理意义上的磨削力计算公式,应用单磨粒热模型得出了热量分配比,采用矩形分布热源计算了磨削热流量；采用数值有限元方法建立了螺旋锥齿轮3D单齿模型。在此基础上,运用热传导理论、热弹塑性理论,对螺旋锥齿轮磨削温度场进行了力热耦合的有限元仿真分析,并进行了实验验证。采用PRANDTL-REUSS方法,建立了磨削界面应力应变场本构关系,仿真分析了螺旋锥齿轮不同齿面磨削位置的应力与应变场分布。
螺旋锥齿轮磨削残余应力及其影响因素研究。结合螺旋锥齿轮啮合原理,运用矢量分析法建立齿面方程,通过“自底向上”的实体建模方法建立了分析螺旋锥齿轮磨削残余应力的实体模型。根据VonMises屈服准则、Mises流动准则和MISO模型建立了齿轮的材料关系模型。按照Gleason接触原理,得出了磨削基本参数的数学模型。基于力热耦合,对螺旋锥齿轮磨削残余应力进行了模拟分析,并进行了实验验证,得出了磨削残余应力随磨削工艺参数变化的规律。
螺旋锥齿轮磨削表面粗糙度研究。运用空间坐标变换原理,通过构造弧齿锥齿轮展成磨削的齿面坐标系、刀具切削面和磨削啮合方程,建立了磨削齿面的数学模型。根据磨削表面粗糙度的包络形成机理及其影响因素分析,采用齿面网格节点的约束求解法计算磨削加工轨迹；然后,由沿齿高方向的各横向截面上2D理论残留面积高度,得出3D理论残留面积高度,并考虑塑性侧向隆起现象,建立了螺旋锥齿轮磨削表面粗糙度的理论模型,并进行了实验验证,得出了磨削工艺参数对磨削表面粗糙度的影响规律。
螺旋锥齿轮磨削表层性态实验研究。运用力热耦合机理和位错理论,实验检测与分析了螺旋锥齿轮磨削表层显微硬度、组织的变化规律。通过对螺旋锥齿轮磨削温度、表层显微硬度与组织的检测与分析,得出了产生磨削烧伤的临界条件,获得了磨削烧伤与裂纹的生成规律与影响因素。
在上述的磨削界面力热耦合与表面性能生成机理研究基础上,进行了螺旋锥齿轮磨削工艺参数优选与磨削表面性能的实验优化分析。根据磨削正交实验结果,采用极差分析法和方差分析法,获得了螺旋锥齿轮磨削工艺参数优选配置。运用多元非线性最小二乘法,得出了磨削评价指标的实验回归模型。通过磨削表面性能的实验优化分析,磨削表面粗糙度Rα值比一般磨削工艺下要小0.1μm以下,其它磨削表面综合性能良好,为螺旋锥齿轮磨削表面质量的提高提供了依据。
Spiral bevel gears are the key parts in the national defense, energy, carry, equipment manufacturing and traffic areas, and so on. Its NC grinding method is widely used in its precision machining. As the space shape and processing of spiral bevel gears are complicated, the key grinding technologies have been monopolized by companies such as Gleason in the long term. The researcher in China has also developed the grinding machines of spiral bevel gears in the past decade, but it has been difficult to improve the grinding quality in manufacturing spiral bevel gears. The grinding quality of grinding tooth machines produced by Gleason Corporation is up to two precision, but at present, the ones in China is 4-6 precision, and the grinding surface roughness is not stable, it is easy to produce grinding burn, cracks, and other grinding surface quality defects. The grinding tooth quality of spiral bevel gears is closely related to the grinding tooth machine and process. Therefore, it is a fundamental way to solve our problems of grinding quality of spiral bevel gears that the body precision of grinding tooth machine is improved, the grinding tooth mechanism is understood, and the optimum pre-control of grinding parameters is achieved. However, now there is the serious lack of research on grinding mechanism and process parameters control in China. Taking increase grinding surface quality as the goal, according to the machining principle and process characteristic of spiral bevel gears, the thesis carries out the research on mechanism of thermo-mechanical coupling on grinding interface and surface performance generating of spiral bevel gears. The main contents are as follows.
Study on the mechanism of thermo-mechanical coupling on grinding interface of spiral bevel gears. According to the six axis five linkage NC machining principle of spiral bevel gears, its adjusting calculation and grinding mechanism analysis were made, and the physical meaning formulas of grinding forces were built. The heat distribution ratio was gotten by applying the thermal model of a single grinding grit, the heat flux was computed by using a rectangle distributing heat source, and the 3D single tooth model of spiral bevel gear was established by applying the finite element method. On the basis of researches of thermo-mechanical coupling, the grinding temperature field of spiral bevel gears was simulated and analyzed by using theories of heat conduction and the thermo-elastic-plastic, and it was verified by test. The constitutive relationships of stress and deformation fields on grinding interface have been set up by applying PRANDTL-REUSS method, and the distribution of stress and deformation fields at different location of grinding tooth were simulated and analyzed.
Study on the grinding residual stresses of spiral bevel gears and its influencing factors. Combined with meshing principle of spiral bevel gears, tooth surface equations were built by applying vector analysis method, and the solid model of analyzing grinding tooth residual stresses was established by applying the bottom-up solid modeling method. Based on the Von Mises yield criterion, the Mises flow rule and the MISO model, the material relationship model of the gears was built. According to the Gleason contact principle, the mathematical models of basic grinding parameters were gotten. Based on the thermo-mechanical coupling, the grinding residual stresses of spiral bevel gear were simulated and verified by experiment, and its change laws with the variation of process parameters were obtained.
Study on the grinding surface roughness of spiral bevel gears. According to the principle of space coordinates transformation, the mathematical models of grinding tooth of spiral bevel gear were set up by constructing the tooth surface coordinate system, cutting tool surface and grinding mesh equation of spiral bevel gears. Based on the cutter enveloping principle and analysis of influencing factors of surface roughness, the grinding trajectory was computed by using the constraint solving method of tooth surface grid nodes. Then, the 3D theoretical residual area heights were translated from 2D's ones of cross section along tooth depth, and the theoretical surface roughness model of grinding tooth of spiral bevel gear was built by taking into account a plastic side upheaval phenomenon, and the model was examined by test. The changing regularity of surface roughness affected by the grinding process parameters was reached.
Experiment study on the grinding surface layer behavior of spiral bevel gears. The change regularity of micro-hardness and structure of grinding surface layer of spiral bevel gears were tested and analyzed by applying the mechanism of the thermo-mechanical coupling and dislocation theory. Through the test and analysis of temperature, micro-hardness and structure of grinding surface layer of spiral bevel gears, the critical condition of grinding burn was obtained, and the generating rules and its influencing factors of grinding burn and cracks were gotten.
Based on the above study of mechanism of thermo-mechanical coupling on grinding interface and surface performance generating, the parameters optimization and the test optimal analysis of grinding surface performance of spiral bevel gears were carried out. According to the results of grinding orthogonal test, the optimizing configuration of grinding process parameters of spiral bevel gears was obtained by using range and variance analysis method. Then, the test regression models of grinding evaluating indicators were conducted by using multivariate nonlinear least squares method. Through the test optimal analysis of grinding surface performance, the value of grinding surface roughness Rαwas more less 0.1μm than ones of the average grinding process, and other comprehensive performance of grinding surface were better. These provided a basis for improvement of grinding surface quality of spiral bevel gears.
引文
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